Article of Footwear Including Full Length Composite Plate

ABSTRACT

A full length composite plate to be used as part of an outsole assembly in an article of footwear is disclosed. The full length composite plate comprises a composite material that has a certain percent elongation. The full length composite plate can include a heel cup for heel stability and improved traction. The full length composite plate also can include two angled portions along an arch region that provide arch support, as well as two flattened edges along the arch region to minimize or eliminate buckling. The forefoot region can be relatively flatter than the arch and heel regions, and notches are preferably included along a portion of the forefoot to increase flexibility.

This application is a continuation of U.S. Patent Publication Number US2011/0023327 A1, published Feb. 3, 2011 (U.S. patent application Ser.No. 12/902,630, filed Oct. 12, 2010), which is a division of U.S. Pat.No. 7,832,117, issued Nov. 16, 2010 (U.S. patent application Ser. No.11/458,044, filed Jul. 17, 2006), both of which are herein incorporatedby reference in their entirety.

BACKGROUND

1. Field

The present invention relates generally to footwear, and in particularthe present invention relates to a composite plate in footwear outsoles.

2. Description of Related Art

Modern footwear generally requires two competing and often contradictorydemands: specific stiffness and reduced weight. Specific stiffnessrefers to stiffness per unit weight. Generally, increasing specificstiffness and durability requires additional material and, subsequently,additional weight. Reducing weight generally requires reducing materialand in turn, sacrificing strength. To meet the need for increasingstrength and durability, while at the same time, reducing weight,designers have proposed the use of composite materials, usually in theform of a composite plate.

While composite materials provide increased strength without increasedweight, their use in articles of footwear has been difficult toimplement and limited. The composite plate is usually only found in oneportion of the footwear, usually either in the heel or the forefoot.Though partial composite plates provide the necessary structure in thedesired region of the footwear while allowing the footwear to remainlightweight, full length composite plates have not been previously usedas part of any type of athletic footwear. This is due to the particularstructure of some composite materials, which often rupture or buckleunder the stresses encountered during normal use. In particular,previous composite plates have been too rigid and inflexible, and couldnot be used where flexibility was required.

Vas (U.S. Pat. No. 6,425,193) discloses a full length composite platethat is composed of a metal matrix containing graphite and ceramic whichis impregnated with a metal alloy. This sort of composite plate does notmeet the requirement of being lightweight, as is most desirable in manytypes of footwear, including those used by athletes.

In general, there is a need for a lightweight full length compositeplate that could be used as the primary structural component of varioustypes of footwear. The desired full length composite plate would allowfor maximum support in the heel and arch and provide proper structureand flexibility in the forefoot region, while at the same time, helpingto maintain the desired weight reduction.

SUMMARY

An article of footwear including a full length composite plate isdisclosed. In one aspect, the invention provides an article of footwearcomprising: an upper and an outsole assembly; the outsole assemblyincluding a full length composite plate; and where the full lengthcomposite plate has a percent elongation greater than 2 percent.

In another aspect, the percent elongation is greater than 3 percent.

In another aspect, the full length composite plate comprises a firstmaterial and a second material.

In another aspect, the first material is lightweight and flexible andthe second material is more rigid than the first material.

In another aspect, the full length composite plate includes a firstlayer comprised of the first material and is attached to the secondlayer comprised of the second material.

In another aspect, the second layer is comprised of the second materialand is attached to a first layer one side and a third layer on a secondside.

In another aspect, the third layer is comprised of the first materialand is attached to the second layer and a fourth layer, wherein thefourth layer is comprised of the second material.

In another aspect, the fourth layer is comprised of the second materialand is attached to the third layer and a fifth layer.

In another aspect, the fifth layer is comprised of the first materialand is attached to the fourth layer and a sixth layer.

In another aspect, the sixth layer is comprised of the second materialand is attached to the fifth layer and a seventh layer.

In another aspect, the seventh layer is comprised of the first material.

In another aspect, the first material is TPU.

In another aspect, the second material is a woven carbon fiber.

In another aspect, the first layer is disposed adjacent to a first tielayer.

In another aspect, the seventh layer is disposed adjacent to a secondtie layer.

In another aspect, the first and second tie layers have a thickness of100 microns.

In another aspect, the invention provides an article of footwearcomprising: an upper and an outsole assembly; the outsole assemblyincluding a full length composite plate; the full length composite platecomprising a first portion and a second portion; and where the firstportion is more flexible than the second portion.

In another aspect, the first portion is associated with the forefoot.

In another aspect, the first portion is a forefoot region.

In another aspect, the first portion is an arch region.

In another aspect, the first portion is a heel region.

In another aspect, the invention provides an article of footwearcomprising: an upper and an outsole assembly; the outsole assemblyincluding a full length composite plate; the composite plate having anarch region associated with the arch of a foot; the arch regionincluding a lateral portion, a medial portion, and a central portiondisposed between the lateral portion and the medial portion; and wherethe arch region includes at least one angled portion.

In another aspect, the at least one angled portion is disposed along thecentral portion.

In another aspect, the at least one angled portion is disposed along thelateral portion.

In another aspect, the at least one angled portion is disposed along themedial portion.

In another aspect, the invention provides an article of footwearcomprising: an upper and an outsole assembly; the outsole assemblyincluding a full length composite plate; the composite plate including aheel region associated with the heel of the foot; the heel regionincluding an outer periphery and a central portion; the outer peripheryincluding a medial portion, a lateral portion, and a rear portion; andwhere a portion of the outer periphery is angled with respect to thecentral portion.

In another aspect, the angled portion of the outer periphery is disposedon the lateral portion.

In another aspect, the angled portion of the outer periphery is disposedon the medial portion.

In another aspect, the angled portion of the outer periphery is disposedalong the rear portion.

In another aspect, the invention provides an article of footwearcomprising: an upper and an outsole assembly; the outsole assemblyincluding a full length composite plate; the full length composite plateincluding an outer material; the outsole assembly also including treadelements; and where the tread elements are secured directly to the outermaterial of the full length composite plate.

In another aspect, the outer material and the tread elements comprisethe same material.

In another aspect, the outer material and the tread elements comprisedifferent materials.

In another aspect, the invention provides a method of making an articleof footwear comprising the steps of: associating a full length compositeplate with a first side of a molding base, a first surface of the fulllength composite plate confronting the first side of the molding base,the full length composite plate also including a second surface disposedopposite the first surface; associating a first side of an upper moldwith the first side of the molding base, enclosing the full lengthcomposite plate within a central cavity disposed within the upper mold;filling the central cavity with a liquid or viscous substance through atleast one injection channel in the upper mold; and where the liquid orviscous substance fills substantially the entirety of the central cavityand contacts the second side of the full length composite plate.

In another aspect, the central cavity contains at least one secondarycavity disposed along, and in fluid communication with, an outerperiphery of the central cavity.

In another aspect, the secondary cavity is shaped for molding a tractionelement.

In another aspect, the upper mold is compressed against the molding baseunder enough pressure to keep the liquid or viscous substance confinedto a region bounded by the central cavity and a portion of the moldingbase exposed to the central cavity.

In another aspect, a central cavity rim disposed along the first side ofthe upper mold has a perimeter larger than a perimeter of the firstsurface of the full length composite plate.

In another aspect, the central cavity includes more than one injectionchannel.

In another aspect, the invention provides an article of footwearcomprising: an outsole assembly; the outsole assembly including a fulllength composite plate; and where the full length composite plate has aflex angle between 5 and 70 degrees.

In another aspect, the full length composite plate has a flex anglebetween 15-30 degrees.

In another aspect, the full length composite plate has a flex anglebetween 37-42 degrees.

In another aspect, the full length composite plate has a flex anglegreater than 15 degrees.

In another aspect, the full length composite plate has a flex anglegreater than 15 degrees.

In another aspect, the full length composite plate has a flex anglegreater than 30 degrees.

In another aspect, the full length composite plate has a flex anglegreater than 45 degrees.

Other systems, methods, features and advantages of the invention willbe, or will become apparent to one with skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features andadvantages be included within this description, be within the scope ofthe invention, and be protected by the following claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the invention. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 is an exploded view of a preferred embodiment of an article offootwear;

FIG. 2 is an isometric view of a preferred embodiment of a full lengthcomposite plate;

FIG. 3 is a plan view of a preferred embodiment of full length compositeplate;

FIG. 4 is a plan view of a preferred embodiment of a full lengthcomposite plate stretched under tension;

FIG. 5 is an isometric view of a preferred embodiment of a full lengthcomposite plate stretched under tension;

FIG. 6 is an isometric view of a preferred embodiment of full lengthcomposite plate bending;

FIG. 7 is an enlarged view of a preferred embodiment of the region offull length composite bending;

FIGS. 8 and 9 are cross sectional views of preferred embodiments of thecomposite materials that are layered to form a full length compositeplate;

FIG. 10 is an exploded oblique view of a preferred embodiment of thelayering structure of a composite materials in a full length compositeplate;

FIG. 11 is an isometric view of a preferred embodiment of an arch regionof a full length composite plate;

FIG. 12 is a cross sectional view of a preferred embodiment of an archregion of a full length composite plate;

FIG. 13 is an isometric view of a preferred embodiment of a heel cup;

FIG. 14 is a schematic view of a preferred embodiment of a first step ofa method for making an outsole assembly;

FIG. 15 is a schematic view of a preferred embodiment of a second stepof a method for making an outsole assembly;

FIG. 16 is a schematic view of a preferred embodiment of a third step ofa method for making an outsole assembly;

FIG. 17 is a schematic view of a preferred embodiment of an outsoleassembly;

FIG. 18 is a cross sectional view of a preferred embodiment of an edgeof a full length composite plate; and

FIG. 19 is a plan view of an alternative embodiment of an outsoleassembly with a bending region.

DETAILED DESCRIPTION

A full length composite plate is disclosed here. The term “full lengthcomposite plate” as used throughout the entirety of this specification,including the claims, is defined as any composite plate which canprovide support to portions of the forefoot, portions of the arch, andportions of the heel of the foot simultaneously.

FIG. 1 shows an exploded view of a preferred embodiment of an article offootwear 100. Article of footwear 100 includes an upper 102. Upper 102could be made of any material, preferably a lightweight fiber. In someembodiments, upper 102 is composed of many different materials. Articleof footwear 100 includes outsole assembly 103. Outsole assembly 103includes full length composite plate 104. Article of footwear 100 may bea running shoe, a soccer shoe, a cross training shoe, a basketball shoeor any other article of footwear. Although in this embodiment there isno midsole, some embodiments may include a midsole.

In some embodiments, outsole assembly 103 may include a tread element130. Outsole assembly 103 may also include other kinds of treadelements. In some embodiments, these tread elements may be directlyattached to full length composite plate 104. Full length composite plate104 includes an outer material 105. In some embodiments, tread element130 may be secured directly to outer material 105. Outer material 105may comprise the same material as tread element 130, or outer material105 may be composed of a different material. Similarly, multiple treadelements may be secured directly to outer material 105. The multipletread elements may comprise the same or different materials than outermaterial 105.

FIG. 2 is an isometric view of a preferred embodiment of full lengthcomposite plate 104. Full length composite plate 104 includes heelregion 106, arch region 108 and forefoot region 110. Arch region 108 isdisposed between heel region 106 and forefoot region 110. Heel region106 includes heel cup 107. Heel cup 107 includes heel outer periphery150 and central portion 118. Arch region 108 includes central portion120. Arch region 108 also includes medial portion 122 and lateralportion 124. In some embodiments, forefoot region 110 may include raisedforward rim 140.

Full length composite plate 104, shown in FIG. 2, is intended for anarticle of footwear designed for a wearer's right foot. Generallyanother full length composite plate that is the mirror image ofcomposite plate 104 would be manufactured for an article of footweardesigned for a wearer's left foot.

In the past, composite plates have generally been found only in aportion of an article of footwear. The composite plate may be placed inthe region of the midsole that engages the heel, or it may be placed inthe region of the article of footwear that engages the ball of the footand toes. Under most circumstances, previous composite plates wereunable to support the entire length of the foot simultaneously. This isbecause previous full length composite plates buckled or ruptured undernormal stresses applied to an article of footwear during use. In otherwords, previous composite materials were too stiff and inflexible, andcould only be used in small, localized areas.

However, it is possible to select a composite plate material from whicha full length composite plate may be manufactured and used as a supportstructure for the forefoot, arch, and heel regions of the foot. Aprimary characteristic of the composite plate material is its percentelongation. Percent elongation is a standard measure of the ductility ofa material. It represents the amount a material can be stretched alongits primary axis before rupturing. Percent elongation is given by thefollowing equation:

Percent Elongation=100(LR−L0)/L0

Here, LR represents the length of the material at the moment it hasruptured, while L0 represents the initial length of the material. Thesemeasurements are preferably taken with respect a central axis.

In a preferred embodiment, the percent elongation of a compositematerial to be used for a full length composite plate is 2 percent. Insome embodiments, the percent elongation for a full length compositeplate may be greater than 2 percent. In other embodiments, the percentelongation can be 3 percent or more.

FIG. 3 shows a plan view of a preferred embodiment of full lengthcomposite plate 104 as viewed from above. In this embodiment, fulllength composite plate 104 is at rest (unstressed) and has a length L0,as measured along central axis 302 that runs from the tip of heel region106 to the tip of forefoot region 110.

FIG. 4 is a plan view of a preferred embodiment of full length compositeplate 104 under tension along central axis 302. This tension may beaccomplished by fixing the tip of heel region 106 to base 414 andpulling the opposite end with some tensioning device. Dotted line 408represents the initial of position of tip forefoot region 110. Thedistance from dotted line 408 to base 414 is L0, the original length offull length composite plate 104. Now under tension, full lengthcomposite plate 104 has been elongated to a new intermediate length, LI.Here, full length composite plate 104 has been elongated by an amount(LI−L0). In this position, full length composite plate 104 has beendeformed, but has not ruptured or failed.

FIG. 5 is a plan view of a preferred embodiment of full length compositeplate 104 under tension along central axis 302. Here, the stress appliedto full length composite plate 104 has elongated it so that the distancebetween the tip of forefoot region 110 and base 414 is LR. At thislength, full length composite plate 104 ruptures, as indicatedschematically by small crack 510. In the embodiment shown in FIG. 5,full length composite plate 104 has been stretched by an amount (LR−L0);and small crack 510 is the first sign of rupturing. In otherembodiments, full length composite plate 104 can fail by de-laminating,splitting, or by some other failure mode.

It is unlikely that a full length composite plate serving as a portionof an article of footwear will experience direct tension along itsprimary axis. Instead, it is much more likely that the full lengthcomposite plate will bend in various ways. Preferably, a full lengthcomposite plate is constructed from materials that allow it to bend by apredetermined amount without rupturing. Referring to FIG. 6, a preferredembodiment of full length composite plate 104 may experience bending. Asvarious stresses are applied to full length composite plate 104 by thefoot and surface during the use of an article of footwear, bending mayoccur. Bending could occur anywhere within composite plate 104. In theexample shown in FIG. 6, bending occurs at bending region 502. Inparticular, bending occurs with respect central axis 500. However, anyother regions of full length composite plate 104 could be bent insimilar ways due to the usual stresses applied to portions of the fulllength composite plate during the use of article of footwear 100.

FIG. 7 is an enlarged view of a preferred embodiment of bending region502. In the embodiment shown in FIG. 7, inner side 608 of full lengthcomposite plate 104 is disposed closest to the foot during motion, andouter side 610 of full length composite plate 104 is disposed closest tothe surface during motion. Typical motions that occur during the use ofan article of footwear will result in bending of full length compositeplate 104 in local regions, such as bending region 502.

In this embodiment, a portion of full length composite plate 104 hasbeen bent away or flexed from its original position 500 by a flex angleT. During bending, compressive loads are applied to inner surface 608,while tensile loads are applied to outer surface 610. Neutral surface604 is the surface through which there is no net force. Between neutralsurface 604 and inner surface 608 compressive loads are increased alongsurfaces parallel to neutral surface 604, reaching a maximum at innersurface 608. Likewise between neutral surface 604 and outer surface 610tensile loads are increased along surfaces parallel to neutral surface604, reaching a maximum at outer surface 610. The area between neutralsurface 604 and outer surface 610 is experiencing tensile loads andtherefore will undergo some local elongation.

In general, the flex angle T of a composite plate is related to thestrain ε applied to the composite plate. In some mathematical models,the strain ε is linearly related to the flex angle T of a compositeplate. As the flex angle T of the composite material changes, so willthe strain ε. Generally, the higher the flex angle T, the higher thestrain ε.

To actually relate flex angle T to strain ε, the thickness of thematerial and the flex zone length are needed. In one example, thethickness is about 1 mm and the flex zone length is about 20 mm. In thisexample, to accommodate a flex angle T of 60 degrees, the necessarystrain is ε=2.9%. In a second example, where the thickness is about 2mm, a flex angle T of 60 degrees causes a strain of about 5.8%. The flexzone length is selected to accurately model the actual behavior of thehuman foot, and the natural bending motion the human foot is likely toimpose on an article of footwear being worn.

Because strain is a measure of the change in length of a material, therelationship between strain and percent elongation is straightforward.Percent elongation is simply the amount of strain applied at therupturing length of a material. Therefore, in order to accommodate agiven flex angle T, the percent of elongation of a material should begreater than the strain caused by flex angle T.

During typical use of an article of footwear, bending will occur.Because bending involves local elongation of a material, materialscomprising the article of footwear may rupture if they are stretchedbeyond their characteristic rupturing length. As part of an article offootwear, a full length composite plate may be designed to endure apredetermined amount of bending in local regions. The materialscomprising the full length composite plate may be chosen from a set ofcandidate materials based on the predetermined amount of bending thatthe full length composite plate is expected to experience during use. Inparticular, acceptable candidate materials for full length compositeplates can be selected based on percent elongation criteria, asdisclosed above. Also, acceptable materials for use as full lengthcomposite plates can be selected based on flex angle T.

Bending region 502 is used here only as an example of a region wherefull length composite plate 104 may undergo stresses that cause it tobend. Full length composite plate 104 may experience stresses that causebending at many different regions. In all these regions, though bendingmay cause elongation in some portions, full length composite plate 104is generally designed to withstand a certain percentage of elongation aspreviously discussed.

As previously discussed, an important characteristic to be considered indesigning a full length composite plate is the flex angle. Depending onthe use of the article of footwear, full length composite plates may bedesigned to accommodate different flex angles.

Generally, a full length composite plate should be able to accommodateflex angles between 5 and 70 degrees, depending on the application. Anyarticle of footwear that needs to accommodate flex angles between 5 and70 degrees may be designed using the characteristics of a full lengthcomposite plate disclosed in this specification. In a preferredembodiment, a full length composite plate may be configured toaccommodate flex angles between 15-30 degrees. These are typical flexangles for a running shoe or a track shoe. In other embodiments, a fulllength composite plate may be configured to accommodate flex anglesbetween 37-42 degrees. An example of a type of shoe that requires thisrange of flex angles is a soccer cleat.

In some embodiments, full length composite plate 104 comprises twodistinct materials. In some embodiments, full length composite plate 104comprises a layered structure. In those embodiments where full lengthcomposite plate includes at least two materials, full length compositeplate 104 preferably includes a first distinct material that islightweight and flexible, and a second distinct material that is morerigid than the first. In a preferred embodiment, the first material isthermoplastic urethane (TPU). In a preferred embodiment, the secondmaterial is a woven sheet of carbon fibers.

FIG. 8 is a cross sectional side view of a preferred embodiment of thelayering of the two distinct materials that comprise the full lengthcomposite plate. Preferably, the two distinct materials alternate inlayers. First fiber layer 704 is disposed between first TPU layer 702and second TPU layer 706. Second fiber layer 708 is disposed betweensecond TPU layer 706 and third TPU layer 710. Third fiber layer 712 isdisposed between third TPU layer 710 and fourth TPU layer 714.

In a preferred embodiment (shown in FIG. 8), a first tie layer 701 maybe disposed adjacent to first TPU layer 702. In a similar manner, asecond tie layer 715 may be disposed adjacent to fourth TPU layer 714.First tie layer 701 and second tie layer 715 may be constructed of TPUas well. First tie layer 701 and second tie layer 714 are preferablymuch thicker than first TPU layer 702, second TPU layer 706, third TPUlayer 710, and fourth TPU layer 714.

In some embodiments, the thickness of the TPU layers 702, 706, 710 and714 may be varied. In some embodiments, the thicknesses may rangebetween 5 and 15 microns. In a preferred embodiment, first TPU layer702, second TPU layer 706, third TPU layer 710, and fourth TPU layer 714are about seven microns thick.

In this embodiment, the thicknesses of the tie layers 701 and 715 may bevaried. Generally, the thicknesses may range from 10 to 500 microns. Insome embodiments, the thicknesses may range from 50 to 200 microns. Insome embodiments, the thicknesses may range from 90 to 110 microns. In apreferred embodiment, the thickness of the tie layers 701 and 715 areabout 100 microns. One hundred microns is an optimized thickness atwhich the strength to weight ratio of a TPU layer in this environment ismaximized.

Additionally, in a preferred embodiment, first tie layer 701 and secondtie layer 715 have a lower melting point than the other TPU layers 702,706, 710, 714. First tie layer 701 and second tie layer 715 may bebonded to a molding material, such as TPU.

In an alternative embodiment, the tie layers may be associated directlywith the fiber layers. In other words, first TPU layer 702 and fourthTPU layer 714 from the previous embodiment may be removed. Instead, thetie layers may be disposed adjacent to fiber layers. By attaching thetie layers directly to the fiber layers, the structural properties ofthe full length composite plate may be modified.

Referring to FIG. 9, a full length composite plate may comprise sevenlayers. First fiber layer 792, second TPU layer 793, second fiber layer794, third TPU layer 795, and third fiber layer 796 are disposed in thesame manner described for the previous embodiment. However, in thisembodiment, first fiber layer 792 is preferably disposed adjacent tofirst tie layer 791. Likewise, third fiber layer 796 is preferablydisposed adjacent to second tie layer 797.

As with the previous embodiment, the thicknesses of the tie layers 791and 797 may be varied. Generally, the thicknesses may range from 10 to500 microns. In some embodiments, the thicknesses may range from 50 to200 microns. In some embodiments, the thicknesses may range from 90 to110 microns. In a preferred embodiment, the thickness of the tie layers791 and 797 are about 100 microns.

Modifying the thicknesses of the tie layers in each embodiment maychange the bonding properties between the tie layers and the fiberlayers. Additionally, modifying the thicknesses of the tie layers mayvary the structural properties of the full length composite plate. Insome embodiments, the flex angle may be varied. In some embodiments, thepercent elongation may be varied.

In general, each fiber layer 704, 708 and 712 may be orienteddifferently. Preferably, the weave geometry comprising each fiber layer704, 708 and 712 may be disposed at angles with respect to one another.By changing the relative orientation of the respective weave geometries,the structural properties of the full length composite plate may bemodified.

Referring to FIG. 10, an illustrative embodiment of the orientation offirst fiber layer 704, second fiber layer 708, and third fiber layer 712is shown. Seen here as an exploded oblique view, each of the individualfiber layers 704, 708, 712 are preferably disposed so that the weavingpatterns are oriented in different directions. In the followingdescription, the term weft refers to the fibers in a weave oriented in ahorizontal, or left to right direction. The term warp refers to thefibers in a weave oriented in a vertical or top to bottom direction.Generally, the weft and warp are always set at right angles to oneanother.

In the embodiment shown in FIG. 10, first fiber layer 704 includes firstlongitudinal axis 722, oriented along the length of the article offootwear. For clarity, a first portion 720 of the weaving pattern offirst fiber layer 704 is shown. In a preferred embodiment, the weavingpattern comprises the entirety of first fiber layer 704. In a preferredembodiment, first weft 760 is set at a first angle A1 from firstlongitudinal axis 722. Likewise, first warp 761 is preferably set at asecond angle A2 from first longitudinal axis 722.

In a preferred embodiment, second fiber layer 708 includes secondlongitudinal axis 732, oriented along the length of the article offootwear. As with first fiber layer 704, only a second portion 730 ofthe weaving pattern of second fiber layer 708 is shown. In a preferredembodiment, the weaving pattern comprises the entirety of second fiberlayer 708. In a preferred embodiment, second weft 762 is set at a thirdangle A3 with respect to second longitudinal axis 732. Likewise, secondwarp 763 is preferably set at a fourth angle A4 from second longitudinalaxis 732.

In a manner similar to first fiber layer 704 and second fiber layer 708,third fiber layer 712 preferably includes third longitudinal axis 742,oriented along the length of the article of footwear. As with the otherfiber layers 704, 708, only a third portion 740 of the weaving patternof third fiber layer 712 is shown. In a preferred embodiment, theweaving pattern comprises the entirety of third fiber layer 712. In apreferred embodiment, third weft 764 is set at a fifth angle A5 fromthird longitudinal axis 742. Likewise, third warp 765 is preferably setat a sixth angle A6 from third longitudinal axis 742.

In general, each angle A1, A2, A3, A4, A5, and A6 may be any angle. Insome embodiments, the weft and warp angles will be identical for each ofthe fiber layers 704, 708, and 712. In a preferred embodiment, thirdangle A3 and fourth angle A4 are 90 and 0 degrees respectively. Also,second angle A2 and fifth angle A5 are preferably less than 45 degreesfrom their respective axes, while first angle A1 and sixth angle A6 arepreferably between 45 and 90 degrees.

The characteristics of a full length composite plate may be modified bychanging the orientation of each fiber layer with respect to oneanother. That is, by changing the angles A1, A2, A3, A4, A5, and A6. Insome cases, the percent elongation of the full length composite platemay be modified by changing angles A1, A2, A3, A4, A5, and A6. In somecases, the flex angle of the full length composite plate may be modifiedby changing angles A1, A2, A3, A4, A5, and A6.

In one embodiment, to increase the flexibility of the full lengthcomposite plate, the weave orientation of each fiber layer 704, 708, and712 may be similar and may be set at 45 degrees angles to a longitudinalaxis. That is: A1 is +45 degrees, A2 is −45 degrees, A3 is +45 degrees,A4 is −45 degrees, A5 is +45 degrees and A6 is −45 degrees. Thisarrangement helps to improve flexibility.

Any suitable material could be used as the fiber layer. In an exemplaryembodiment, a carbon fiber layer is used.

Referring to FIG. 11, a preferred embodiment of arch region 108 mayinclude medial portion 122 and lateral portion 124. Arch region 108 mayalso include central portion 120. Preferably, arch region 108 includesprovisions to supply stiffness to the arch as well as provisions tominimize or eliminate buckling of full length composite plate 104. Insome situations, compressive loads may be applied to full lengthcomposite plate 104 at forward region 802 and rear region 804, as seenin FIG. 10. These compressive loads may cause compression of full lengthcomposite plate 104 along central axis 806. If the compressive loads arestrong enough, full length composite plate 104 may buckle.

Referring to FIG. 12, the geometry of full length composite plate 104along arch region 108 is best seen in a cross sectional view.Preferably, medial portion 124 includes first flat portion 860.Likewise, lateral portion 122 preferably includes second flat portion862. Central portion 120 preferably includes first angled portion 864and second angled portion 866. Central portion 120 may also includerounded portion 868. Preferably, first flat portion 860 and second flatportion 862 are both generally coincident with surface 850. Roundedportion 868 preferably follows contour 899 of arch region 108 along thelength of the article of footwear. In some embodiments, contour 899 maybe the shape of the last of article of footwear 100. First angledportion 864 and second angled portion 866 are preferably not parallel tosurface 850. In a preferred embodiment, first angled portion 864 andsecond angled portion 866 are both rounded.

In a preferred embodiment, first angled portion 864 and second angledportion 866 are configured to supply stiffness to arch region 108. Insome embodiments, second angled portion 866 may be slightly larger inorder to increase stability by slowing the rate of pronation alongmedial side 124. Furthermore, first flat portion 850 and second flatportion 862 are preferably configured to minimize or eliminate bucklingwhen flexed.

In a preferred embodiment, full length composite plate 104 includesprovisions for increasing heel stability as well as for improvingtraction. Referring to FIG. 13, a preferred embodiment of heel region106 of full length composite plate 104 may include heel cup 107. Here,the arch region and the forefoot region are shown in phantom. Heel cup107 includes heel outer periphery 150 and central portion 118. In apreferred embodiment, heel outer periphery 150 is disposed at an angleto central portion 118. Heel outer periphery 150 includes medial portion1112, lateral portion 1116, and rear portion 1114.

As heel cup 107 is associated with the heel of the foot, the variousportions of the heel cup are intended to provide support for the heel.In particular, central portion 118 is disposed under the heel duringuse. Likewise, medial portion 1112 may be disposed against the medialside of the heel during use. Lateral portion 1116 may be disposedagainst the medial side of the heel during use. Rear portion 1114 may bedisposed against the rear of the heel during use.

During use of the article of footwear, there may be a tendency for theheel to move outside of the heel region of the outsole. Medial portion1112, lateral portion 1116, and rear portion 1114 each act to keep theheel confined to the heel region of the outsole.

In some embodiments, heel cup 107 may be used simultaneously with aminimal heel counter. This minimal heel counter may be either internalor external. In some embodiments, heel cup 107 may be used instead of aheel counter.

Although in this embodiment, tread elements are directly attached tofull length composite plate 104, other embodiments may include treadelements that have been over-molded on a full length composite plate, aspart of an outsole assembly. The over-molded material may include treadelements, as well as other structural elements for the outsole assembly.Embedding the full length composite plate in the molded material may beaccomplished by using an over-molding technique.

In FIG. 14, a schematic diagram of a preferred embodiment of a firststep of a method for making an outsole assembly is shown. The method ofmaking an outsole assembly includes a full length composite plate 1220,a molding base 1224, and a mold 1260. Molding base 1224 provides supportfor full length composite plate 1220 during the over-molding process.Mold 1260 is used to create the over-mold to be attached directly tofull length composite plate 1220, which may include tread elements aswell as other structural features. In some embodiments, full lengthcomposite plate 1220 can also create support and shutoff in regionswhere over-molding is not desired.

Full length composite plate 1220 includes a first side 1226 and a secondside 1228. Molding base 1224 includes a first side 1230 and a secondside 1232. Mold 1260 includes a first side 1270 and a second side 1272.Mold 1260 also includes molding channel 1262 and central cavity 1264.Central cavity 1264 is manufactured to yield the desired molded portionfor full length composite plate 1220, once a molding material has beenadded. Molding channel 1262 provides a means for filling central cavity1264 with a molding material. Molding channel 1262 is preferably influid communication with central cavity 1264 through first orifice 1263.Second orifice 1265 is preferably disposed along first mold side 1270.

Although in this embodiment only one molding channel is shown, otherembodiments may include multiple molding channels. These moldingchannels may be used in a similar way to that of molding channel 1262,providing a means for filling central cavity 1264 with a moldingmaterial.

Central cavity 1264, when filled with a molding material, yields themolded portion of an outsole assembly. In some embodiments, centralcavity 1264 includes at least one secondary cavity 1280. This secondarycavity is disposed along the periphery of central cavity 1264. Thesecondary cavity may be shaped like a tread element in some embodiments.Multiple secondary cavities may also be included in central cavity 1264.Thus, by using central cavity 1264 and secondary cavities, the moldedportion of the outsole assembly may include traction elements and othergeneral structure for the molded portion of the outsole assembly.

During the first step in the method of making an outsole assembly,second side 1228 of full length composite plate 1220 is associated withfirst side 1230 of molding base 1224. Full length composite plate 1220is preferably fixed to molding base 1224 via clamp pressure and partgeometry reflected in the mold cavity and core.

FIG. 15 is a schematic diagram of a preferred embodiment of a secondstep of the method for making an outsole assembly. During this secondstep, second side 1272 of mold 1260 is associated with first side 1230of molding base 1224. This step may be accomplished by lowering mold1260 onto molding base 1224, forming central cavity 1264. Referring toFIG. 14, the perimeter of central cavity 1264 along second side 1272 ispreferably larger than the perimeter of both first side 1226 and secondside 1228 of full length composite plate 1220.

FIG. 16 is a schematic diagram of a preferred embodiment of a third stepof the method for making an outsole assembly. During this third step, amolding material 1402, which is preferably in liquid or viscous formduring this step, is injected into central cavity 1264 via mold channel1262. Molding material 1402 preferably fills the entire cavity. Duringthis third step, full length composite plate 1220 is embedded in moldingmaterial 1402. In particular, the first side 1404 of molding material1402 is disposed against first side 1230 of molding base 1224. Firstside 1404 of molding material 1402 is disposed flush with second side1228 of full length composite plate 1220. In some areas, for example,the lateral and/or medial edges of the arch region 1480, moldingmaterial 1402 may sandwich full length composite plate 1220.

FIG. 17 is a schematic diagram of a preferred embodiment of a fourth andfinal step of the method for making an outsole assembly. During thisfourth step, mold 1260 is removed from molding base 1224, after moldingmaterial 1402 has solidified. This step may be accomplished by raisingmold 1260 with respect to molding base 1224. What remains is outsoleassembly 1502, which includes full length composite plate 1220 andmolding 1510. Outsole assembly 1502 may also be removed from moldingbase 1224 during this step.

In some cases, full length composite plate 1220 may be sandwiched bymolding 1510. In some embodiments, the entire full length compositeplate 1220 is sandwiched by molding 1510. In some embodiments, onlyportions of full length composite plate 1220 may be sandwiched bymolding 1510.

In particular, first edge 1604 of full length composite plate 1220 ispreferably covered by molding 1510. As seen in FIG. 18, upper surface1606 of first edge 1604 and lower surface 1608 of first edge 1604 arepreferably both in contact with molding 1510. This arrangement providesa sandwiched structure where molding 1510 encases first edge 1604.

In a similar manner, second edge 1610 of full length composite plate1220 is also preferably covered by molding 1510. As shown in FIG. 18,upper surface 1612 and lower surface 1614 of second edge 1610 arepreferably both in contact with molding 1510. This arrangement providesa sandwiched structure where molding 1510 encases second edge 1610.

This arrangement allows first edge 1604 and second edge 1610 of fulllength composite plate 1220 to be better protected. It may also increasethe area of contact between molding 1510 and full length composite plate1220. Generally, the transition between molding material 1510 and fulllength composite plate 1220 is smooth along first edge 1604 and secondedge 1610. In some embodiments, tread elements may extend from molding1510, projecting in a direction opposite of full length composite plate1220.

FIGS. 14-17 are schematic illustrations of the process by which anover-molding is applied to full length composite plate 1220. In apreferred embodiment, mold 1260 and molding base 1224 would alsopreferably include provisions for receiving and molding around all thephysical features previously discussed as part of a preferred embodimentof full length composite plate 1220. For example, in a preferredembodiment, mold 1260 and molding base 1224 would each be configuredwith portions configured to be disposed adjacent to a first angledportion and a second angled portion of full length composite plate 1220.That is, the first side 1230 (see FIG. 15) of molding base 1224 need notbe flat, but may include curves corresponding to unique features of afull length composite plate. In a similar manner, second side 1272 ofmold 1230 may include curves corresponding to unique features of a fulllength composite plate.

In a preferred embodiment, a full length composite plate may be designedto provide maximum flexibility along the forefoot. In the human footthere is a natural bend line that occurs at a diagonal across theforward region of the foot. In order to provide maximum flexibility, itis desired that components of an article of footwear are designed tobend elastically in this region.

FIG. 19 shows an alternative embodiment of outsole assembly 900 thatincludes full length composite plate 902 and molding 904. Outsoleassembly 900 includes forefoot region 903, arch region 950, and heelregion 952.

Preferably, outsole assembly 900 includes provisions that facilitatebending along forefoot region 903. In FIG. 19, 920 represents thenatural bend line of the foot. Bending region 991 is a region proximateto natural bend line 920. Some embodiments include provisions toincrease the flexibility of bending region 991. In some embodiments,molding slot 930 is provided to allow increased flexibility in bendingregion 991.

In some embodiments, flexibility is increased in bending region 991 ofmolding 904 by reducing the thickness of molding 904 along molding slot930. Additionally, forefoot region 903 is relatively flat when comparedwith arch region 950 and heel region 952. These features allow forefootregion 903 to have increased flexibility in comparison to arch region950 and heel region 952. In particular, a bending region 990 of forefootregion 903 has increased flexibility over arch region 950 and heelregion 952. In some embodiments, bending region 990 may be a regionother than forefoot region 903. In some embodiments, bending region 990may be an arch region or a heel region.

Additionally, full length composite plate 902 may include first angledportion 980 and second angled portion 982. First angled portion 980 andsecond angled portion 982 are preferably wider at first end 984 andsecond end 986 of arch region 950. In a preferred embodiment, firstangled portion 980 and second angled portion 982 are more narrow alongmiddle portion 951 of arch region 950. As previously discussed, firstangled portion 980 and second angled portion 982 add support to archregion 950.

While various embodiments of the invention have been described, thedescription is intended to be exemplary, rather than limiting and itwill be apparent to those of ordinary skill in the art that many moreembodiments and implementations are possible that are within the scopeof the invention. Accordingly, the invention is not to be restrictedexcept in light of the attached claims and their equivalents. Also,various modifications and changes may be made within the scope of theattached claims.

What is claimed is:
 1. A method of making an article of footwearcomprising: associating a full length composite plate with a first sideof a molding base, a first surface of the full length composite plateconfronting the first side of the molding base, the full lengthcomposite plate also including a second surface disposed opposite to thefirst surface; associating a first side of a mold with the first side ofthe molding base, enclosing the full length composite plate within acentral cavity disposed within the mold; filling the central cavity witha liquid or viscous substance through at least one injection channel inthe mold; and wherein the liquid or viscous substance fillssubstantially the entirety of the central cavity and contacts the secondside of the full length composite plate.
 2. The method according toclaim 1, wherein the central cavity contains at least one secondarycavity disposed along, and in fluid communication with, an outerperiphery of the central cavity.
 3. The method according to claim 2,wherein the at least one secondary cavity is shaped for molding atraction element; and the method further comprises forming the tractionelement by filling the at least one secondary cavity with the liquid orviscous substance.
 4. The method according to claim 1, furthercomprising holding the mold against the molding base under enoughpressure to keep the liquid or viscous substance confined to a regionbounded by the central cavity and a portion of the molding base exposedto the central cavity.
 5. The method according to claim 1, wherein acentral cavity rim disposed along the first side of the mold has aperimeter larger than a perimeter of the first surface of the fulllength composite plate and a perimeter of the second surface of the fulllength composite plate.
 6. The method according to claim 1, furthercomprising filling the central cavity with the liquid or viscousmaterial through more than one injection channel in the mold.
 7. Themethod according to claim 1, wherein a central cavity rim disposed alongthe first side of the mold contacts the first side of the molding baseat a location spaced apart from a perimeter of the full length compositeplate, such that a portion of the first side of the molding base betweenthe central cavity rim and the perimeter of the full length compositeplate is exposed to the central cavity.
 8. The method according to claim7, further comprising contacting the portion of the first side of themolding base that is exposed to the central cavity with the liquid orviscous substance, such that the liquid or viscous substance is disposedflush with the first surface of the full length composite plate.
 9. Themethod according to claim 7, further comprising sandwiching at least oneedge of the full length composite plate with the liquid or viscoussubstance.
 10. The method according to claim 9, wherein the at least oneedge comprises at least one of a lateral edge and a medial edge of anarch region of the full length composite plate.
 11. The method accordingto claim 1, wherein associating the full length composite plate with thefirst side of the molding base comprises mating non-flat features of thefull length composite plate with corresponding non-flat features of thefirst side of the molding base.
 12. The method according to claim 1,wherein associating the first side of the mold with the first side ofthe molding base comprises disposing an angled portion of the moldadjacent to a corresponding angled portion of the second surface of thefull length composite plate.
 13. The method according to claim 1,wherein the liquid or viscous substance forms a molding attached to thefull length composite plate; wherein the method further comprisesforming a molding slot in the molding at a bending region of the articleof footwear; and wherein a thickness of the molding is reduced along themolding slot.
 14. The method according to claim 1, wherein the fulllength composite plate comprises a first plurality of layers alternatingwith a second plurality of layers; wherein each layer of the firstplurality of layers comprises a full length non-woven sheet; whereineach layer of the second plurality of layers comprises a full lengthwoven fiber sheet; wherein each layer of the first plurality of layershas a first thickness; wherein each layer of the second plurality oflayers has a second thickness; wherein the full length composite platefurther comprises a first tie layer disposed on a first side of thealternating first and second pluralities of layers and a second tielayer disposed on a second side of the alternating first and secondpluralities of layers opposite to the first side; wherein the first tielayer and the second tie layer each have a third thickness; wherein thethird thickness is greater than the first thickness and the secondthickness; wherein the full length composite plate, as measured as asingle component comprising the first plurality of layers, the secondplurality of layers, the first tie layer, and the second tie layer, hasa percent elongation greater than 2 percent and a thickness less than orequal to approximately 2 mm; wherein the first tie layer provides thefirst surface of the full length composite plate; wherein the second tielayer provides the second surface of the full length composite plate;wherein the method further comprises forming a molding from the liquidor viscous substance in the central cavity; and wherein the liquid orviscous substance solidifies to form a molding that is attached to thefirst tie layer of the full length composite plate.
 15. A method ofmaking an article of footwear comprising: placing a full lengthcomposite plate between a mold and a molding base, wherein the fulllength composite plate has a first side facing the mold and a secondside opposite to the first side and facing the molding base; positioningthe full length composite plate within a central cavity defined by themold and the molding base; injecting molding material into the centralcavity through at least one injection channel in the mold; filling thecentral cavity with the molding material and contacting the first sideof the full length composite plate with the molding material; andwherein the molding material solidifies to form a molding attached tothe first side of the full length composite plate.
 16. The methodaccording claim 15, wherein the full length composite plate has an edge;and wherein the method further comprises applying the molding materialto the edge, to the first side of the full length composite plate at theedge, and to the second side of the full length composite plate at theedge, such that the molding material encases the edge.
 17. The methodaccording to claim 16, wherein the edge comprises one of a lateral edgeand a medial edge of the full length composite plate.
 18. The methodaccording to claim 15, wherein a central cavity rim disposed along afirst side of the mold facing the molding base contacts a side of themolding base facing the first side of the mold at a location spacedapart from a perimeter of the full length composite plate, such that aportion of the first side of the molding base is exposed to the centralcavity; and wherein the method further comprises contacting the portionof the first side of the molding base that is exposed to the centralcavity with the molding material, such that the molding material isdisposed flush with the second side of the full length composite plate.19. The method according to claim 15, wherein the full length compositeplate comprises a first plurality of layers alternating with a secondplurality of layers; wherein each layer of the first plurality of layerscomprises a full length non-woven sheet; wherein each layer of thesecond plurality of layers comprises a full length woven fiber sheet;wherein each layer of the first plurality of layers has a firstthickness; wherein each layer of the second plurality of layers has asecond thickness; wherein the full length composite plate furthercomprises a first tie layer disposed on a first side of the alternatingfirst and second pluralities of layers and a second tie layer disposedon a second side of the alternating first and second pluralities oflayers opposite to the first side; wherein the first tie layer and thesecond tie layer each have a third thickness; wherein the thirdthickness is greater than the first thickness and the second thickness;wherein the full length composite plate, as measured as a singlecomponent comprising the first plurality of layers, the second pluralityof layers, the first tie layer, and the second tie layer, has a percentelongation greater than 2 percent and a thickness less than or equal toapproximately 2 mm; wherein the first tie layer provides the first sideof the full length composite plate; wherein the second tie layerprovides the second side of the full length composite plate; and whereinthe molding is attached to the second tie layer of the full lengthcomposite plate.
 20. A method of making an article of footwearcomprising: placing a full length composite plate between a mold and amolding base; wherein the full length composite plate has a first sidefacing the mold and a second side opposite to the first side and facingthe molding base; wherein the full length composite plate defines alongitudinal direction from a rearward heel region of the full lengthcomposite plate to a forward forefoot region of the full lengthcomposite plate; wherein when the full length composite plate is viewedin a cross-section taken generally perpendicular to the longitudinaldirection, the full length composite plate has a flat medial portion, aflat lateral portion, and an angled central portion in between, andprotruding away from, the flat medial portion and the flat lateralportion; positioning the full length composite plate within a centralcavity defined by the mold and the molding base; disposing the angledcentral portion of the full length composite plate in a correspondingangled portion of the molding base; injecting molding material into thecentral cavity through at least one injection channel in the mold;filling the central cavity with the molding material and contacting thefirst side of the full length composite plate with the molding material;encasing an edge of the flat medial portion with the molding material;encasing an edge of the flat lateral portion with the molding material;and wherein the molding material solidifies to form a molding that isattached to the first side of the full length composite plate and thatis attached to the second side of the full length composite plate at theedge of the flat medial portion and at the edge of the flat lateralportion.